Bevel Gear, Replacing
Bevel gear
Special tools:
998 5972 JACK 998 5972 Jack
999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket
999 7057 Counterhold 999 7057 Counterhold
999 7076 Lever 999 7076 Lever
Note! Some variation may occur. However, the essential information in the illustrations is always correct.
Removal
Preparations
Note! Check that the parking brake is not applied or that the gear selector is in position P.
Only D5244T/T2
Remove the heat deflector plate.
Disconnecting the front suspension components
Raise the car.
Remove:
- the right front wheel
- the screw for the drive shaft and wheel hub
Removing front end components, continued
Remove:
- the nut for the ball joint / control arm. Counterhold the ball joint pinion with a Torx wrench so that the boot does not twist
Note! Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut.
For steel control arm, see: Ball joint, replacing Service and Repair
- the splashguard under the engine.
Draining AW transmission oil
Place a glass gauge in the oil collection container.
Remove the drain plug.
Measure the drained volume of oil.
Draining the M66 transmission oil
Collect the oil in a container.
Remove the drain plug (1) and drain the oil.
Install the plug with a new gasket.
Tighten to 35Nm.
Removing spring strut from control arm
Unhook the control arm from the ball joint. Use lever 999 7076 Lever 999 7076 Lever
Note! Position the tool so that it does not damage the boot on the ball joint.
Removing the drive shaft
Press out the wheel spindle. Detach the drive shaft from the hub. Do not damage the drive shaft boot. Use a tensioner band to pull the spring strut backwards.
Remove the screws from the bearing cap for the drive shaft. Pull the drive shaft straight out.
Note! Do not pull the outer part of the shaft. Doing so could damage the axial stops in the joints.
Removing the propeller shaft
Remove the front member from the body and exhaust pipe/catalyst.
Remove the brake line from the member's mounting.
Removing the propeller shaft, front
Note! Only mark the position of the propeller shaft CV joint in relation to the bevel gear's flange if the same bevel gear is to be reused.
Remove the screws from the propeller shaft. Use counterhold 999 5743 Counterhold 999 5743 Counterhold
Press the drive shaft joints together as much as possible.
Remove the screws on left-hand side from the support for the center bearing.
Remove the shaft from the bevel gear and angle it as much as possible.
Leave the end of the shaft resting against the anti-roll bar.
Note! Be careful. Do not damage the heated oxygen sensor (HO2S) or its cable.
Only D5244T/T2
Remove the screws from the charge air pipe.
Remove the hose clamps.
Remove the charge air hose.
Remove the bracket for the catalyst.
Remove the nuts, 3 pcs, at the junction between the turbo and exhaust pipe.
Use easing oil on the stud bolts.
Only D5244T-T3
There are two different types of vibration damper (see this and the next step).
When replacing the bevel gear, transfer the vibration damper to the new bevel gear.
Remove the vibration damper.
Remove the vibration damper.
Only RHD
Remove the collision protection nuts, 3 pcs.
Press the collision protection towards the right-hand side of the vehicle.
Install new nuts. Torque tighten 50 Nm.
Remove screws for the rear engine pad.
Raise the engine/transmission using a mobile jack.
Removing bevel gear
Fold down the tab on the sub-frame to create a space to remove the bevel gear.
Remove the screws, 5 pcs, for the bevel gear. Pull the bevel gear straight out. Then turn it during removal.
Greasing splines
Note! Use all the grease in the package.
Always grease the splines joint between the transmission and the bevel gear. Greasing is carried out to avoid corrosion between the terminal sleeve and the bevel gear tubular shaft.
Replace the connection sleeve. Refer to: Seal rings, connecting socket, B5254T2, AW50/51 AWD Seal Rings, Connecting Socket
Thoroughly lubricate the splines in the connection sleeve.
Use: grease, 1161748
Installation
Installing the bevel gear
Make sure that the contact faces on the transmission and bevel gear are clean.
Note! Use new screws.
Install the bevel gear.
Lightly tighten the screws alternately.
Tighten the screws alternately to 75 Nm. Tightening Torque
Fold the tab up into place on the sub-frame.
Lower the engine/transmission.
Install the screws for the engine pad.
Tighten to 50 Nm.
Only D5244T/T2
Install the charge air hose.
Tighten the hose clips.
Install screws for the charge air pipe and tighten.
When replacing the bevel gear, transfer the oscillation damper to the new bevel gear. On some markets there is a bracket for the engine block heater. This bracket must also be transferred. Install two washers between the bevel gear and bracket on the lower stud (see spare parts catalog). Install the oscillation damper.
Install the vibration damper.
Install the exhaust pipe on the turbo with new gasket.
Use new nuts. Torque tighten to 30 Nm.
Install the bracket. Torque tighten to 24 Nm.
Installing the propeller shaft
Check that the mating surfaces on the propeller shaft CV joint and flange are clean.
Align the propeller shaft CV joint against the flange.
Install the screws loosely in the support for the center bearing and the propeller shaft
Install the propeller shaft using the marking made earlier.
Tightening the propeller shaft CV joint
Check carefully that the mating surfaces on the propeller shaft and flange are clean.
Use new screws.
Tighten alternately to 10 Nm, see
Then alternately to 25 Nm.
Installing members
Install the front member on the bodywork, exhaust pipe and three-way catalytic converter (TWC). Press the brake pipe into place in the mountings on the member.
Tighten:
- the 4 x M8 screws for the front member
- the 4 x M8 screws for the support for the center bearing
- the 2 x M8 screws for the propeller shaft center bearing.
Installing the drive shaft and bearing cap on the pilot bearing for the shaft
Install the following items:
- drive shaft
- bearing cap. Torque tighten to 24 Nm.
Installing the sealing ring for the CV joint housing on the stub axle
Note! Replace the sealing ring if it is damaged or worn.
Clean around the constant velocity joint before installing the sealing ring.
Carefully install the sealing ring. Ensure that the sealing ring is correctly positioned on the drive shaft.
Installing the drive shaft
Align the drive shaft in the hub.
Depress the control arm. 999 7076 Lever 999 7076 Lever
Align the ball joint in the control arm
Note! Position the tool so that it does not damage the boot on the ball joint.
Checking the oil level in the bevel gear
The bevel gear is supplied filled.
Use: Transmission oil, 1161513
Correct volume is 750 ml.
Note! When checking the oil level: Fill with oil up to the filler plug, then draw out 0.16 L.
Install the filler plug with new gasket. Tighten to 35 Nm.
Installing ball joint nut
Caution! The ball joint pin may not rotate. Use: Torx wrench 40, long version, 951 2927 Torx 40. Long version 951 2927 Torx 40. Long Version as counterhold in order to prevent damaging the rubber boot.
Use: sleeve over nut rear shock absorber 999 5500 SOCKET UPPER NUT REAR SHOCK ABSORBER 999 5500 Socket Upper Nut Rear Shock Absorber and torque wrench.
Note! A counterhold is not required when angle tightening if the joint has been tightened to 50 Nm. The friction between the ball joint and control arm is greater than between the nut and threads on the ball joint.
Torque tighten to 50 Nm, Angle tighten to 40 °. Use bevel protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
For steel control arm, see: Ball joint, replacing Service and Repair
Install the splashguard under the engine.
Installing front suspension components
Install:
- screw for driveshaft/wheel hub. Use new screws. Torque tighten to 35 Nm. Angle tighten to 90°.
- the wheel
- install the wheel studs lightly. Then tighten them crosswise to 140 Nm. Use torque socket 951 2835 Torque socket 19mm S80 951 2835 Torque Socket 19mm S80 if an impact wrench is being used.
Only D5244T/T2
Install the heat deflector plate
Filling with transmission oil, M58/M66
Remove the filler/level plug (2).
Fill oil.
Install the plug with a new gasket. Tighten to 35 Nm.
Filling transmission oil, AW
Fill the same amount of oil through the oil dipstick that was drained.